INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS

INDEX LET-LOK TUBE FITTINGS...................................339 1/16" through - inch 2 mm through 25 mm - metric H500 SERIES....................................................................344 3-Piece ball valves

ONE-LOK TUBE FITTINGS...............................340 1/4",3/8", 1/2", 3/4" 1"

H700 SERIES.....................................................................346 Ball valves with locking device

PIPE LINE..................................................................................341 Precision instrumentation pipe fitting

H6800 SERIES................................................................347 Instrumentation ball valves

HTC ......................................................................................................341 Hi-tech components

H900 SERIES .................................................. Relief valves

...

348

H300 SERIES.......................................................................342 Needle valves

H900-HP SERIES ...................................... High pressure relief valves

.....

352

H400 SERIES.......................................................................343 Check valves

H600 SERIES ...................................................................356 T-type & in-line filters

338

INSTALLATION INSTRUCTIONS

1/16"

through 1" - Inch, 2 mm through 25 mm - Metric

Tube Cutter

To attain a leak-free connection, cut the tubing squarely. Use a good quality tube cutter with the appropriate blade for the tubing. Do not try to reduce the time of cutting by taking deep cuts with each turn of the cutter. This will work harden the tube. Deburr the end of the tube to avoid damage to the fitting and to ensure that the tube reaches the bottom of the fitting.
Hacksaw Cutting

LET-LOK fittings are supplied assembled, finger tight. Diassembly before use can allow the entry of dirt or other particles.
1. Insert the tubing into the LET-LOK fitting.

Check that the tube rests firmly on the fitting shoulder and that the nut is finger tight.
2. Tighten the nut.

In order to cut the tube with a hacksaw and get square ends, cut the tube with guide blocks. If you use this method of cutting, you will need to deburr the tube ends. Warning! Do not hold the tube in a vise at the place where it will be inserted into the fitting (the vise will leave a mark on the tube that may cause leaks, and might cause ovality). Tube Handling Scratches on the tube might cause leaks. Therefore, use caution in handling the tube in order to reduce the possibility of leaks.
Some precautions to be taken: 1. Tubes must not be dragged on the floor. 2. Tubes must not be dragged out of a tubing rack,

11/4 turns of the nut are required for 1/4" (6 mm) and higher. (See Figure A.) 3/4 of a turn of the nut are required for 3/16" (4 mm) and lower. (See Figure B.)

Reassembly Instructions LET-LOK connections may be disconnected and remade repeatedly without loss of the leaktight seal. 1. Before disconnecting, mark the position of the nut in relation to the fitting body. 2. To reassemble, use a wrench to tighten the nut to original position. 3. Tighten slightly with a wrench until you feel a slight rise in torque. Tube Cutting There are two ways to cut tubes: 1. Tube cutter 2. Hacksaw

especially in case of large OD tubes.

Copper Tubing

If you use copper tubing on a rol, be sure to hold the end of the tube, then, move the tubing away from you, so that it can lie on a flat surface.

339

INSTALLATION INSTRUCTIONS

1/4'', 3/8'', 1/2'', 3/4'', 1''

Tube Cutting

There are two ways to cut tubes: 1. Tube cutter 2. Hacksaw

Tube Cutter

One-LOK fittings are supplied assembled, finger tight. Diassembly before use can allow the entry of dirt or other particles.

1. Insert the tubing into the ONE-LOK fitting. Check that the tube rests firmly on the fitting shoulder and that the nut is finger tight. 2. Tighten the nut. 1 1/4 turns of the nut are required. (See Figure A.)

To attain a leak-free connection, cut the tubing squarely. Use a good quality tube cutter with the appropriate blade for the tubing. Do not try to reduce the time of cutting by taking deep cuts with each turn of the cutter. This will work harden the tube. Deburr the end of the tube to avoid damage to the fitting and to ensure that the tube reaches the bottom of the fitting. Hacksaw Cutting In order to cut the tube with a hacksaw and get square ends, cut the tube with guide blocks. If you use this method of cutting, you will need to deburr the tube ends. Warning! Do not hold the tube in a vise at the place where it will be inserted into the fitting (the vise will leave a mark on the tube that may cause leaks, and might cause ovality). Tube Handling Scratches on the tube might cause leaks. Therefore, use caution in handling the tube in order to reduce the possibility of leaks. Some precautions to be taken: 1. Tubes must not be dragged on the floor. 2. Tubes must not be dragged out of a tubing rack, especially in case of large OD tubes. Copper Tubing If you use copper tubing on a rol, be sure to hold the end of the tube, then, move the tubing away from you, so that it can lie on a flat surface.

Reassembly Instructions ONE-LOK connections may be disconnected and remade repeatedly without loss of the leaktight seal. 1. Before disconnecting, mark the position of the nut in relation to the fitting body. 2. To reassemble, use a wrench to tighten the nut to original position. 3. Tighten slightly with a wrench until you feel a slight rise in torque.

340

INSTALLATION INSTRUCTIONS

HAM-LET PRECISION INSTRUMENTATION PIPE FITTINGS

To ensure a leak-tight seal, HAM-LET recommends that you use a pipe-thread sealant on all NPT threads. The most effective sealing method is teflon tape. Tape should be used only on male tapered pipe threads.
Do not use tape on flared, coned or tube fitting ends!

Note: We suggest two wraps for stainless-steel tapered pipe threads. Make sure tape does not overhang the first thread. Otherwise, tape could shred and enter into the fluid system. Cut off excess tape. The connection is now ready for proper makeup.

Clean both male and female tapered threads. Wrap tape in the direction of the male tapered thread spiral.

HTC
HI-TECH COMPONENTS

MAKE UP OF GLANDS n Glands offer a high-purity metal to metal seal for leak-free service in high-vacuum or high-pressure assemblies. n The gasket is compressed by two highly polished beads when the male and female nuts are engaged. n The glands bead-to-bead assembly compresses a soft metal gasket-to-seal. This assembly can be locked by HAM-LETs Grip-Kit (See A below). n Visual test and leak testing are performed through two test ports in opposite locations from the female nut. ASSEMBLY INSTRUCTIONS 1. Be sure to protect all HTC face-seal fittings until assembly and make up. Exercise great care that the sealing surfaces are not scratched, damaged or contaminated in any way during handling and assembly. 2. Always use a clean environment, and always employ proper clean-room protocol for make up and assembly of high-purity fittings and applications.

3. Make up instructions: Tighten the female nut to the male nut/body finger tight. Tighten the female nut 1/8 turn past finger tight. Always torque the female nut while keeping the male nut/body stationary. Face seal connections are remakable - please use a new gasket for each remake.

341

INSTALLATION INSTRUCTIONS

H-300 SERIES
NEEDLE VALVES

1.

Use For maximum valve life, use the valve only within the stated pressure and temperature range, and in accordance with the corrosion resistance of the material.

2. Operation To open the valve, rotate the handle until it comes in contact with the lower gland. This will allow maximum flow through the valve. To close the valve, rotate the handle until the stem tip comes into contact with the seat. Do not use excessive force when closing the valve. Excessive torque applied to the handle may damage both seat and stem tip, particularly the soft seat option. 3. Cleaning the Valve Liquids can be trapped within the valve. If the valve has been used with hazardous media, it must be de-contaminated before disassembly. All personnel involved in the removal and disassembly of the valve should wear appropriate protective clothing, such as face shields, aprons, gloves, etc. 4. Replacing seat and stem seals If there are signs of leakage through the stem area, and further adjustment is not possible, replace the stem seal. If there are signs of leakage across the seat, replace the stem. Warning! For Your Safety The system designer and user have the sole responsibility to select products suitable for their special application requirements to ensure the proper installation, operation and maintenance of the product. Application details, material compatibility and product ratings should all be considered in the individual selection. Improper selection or use of products can cause property damage or personal injury.

5. Procedures Disassembly With the valve clamped firmly in a vise: n Remove the set screw (2) with the appropriate Allen wrench, and remove the handle (1). n Remove packing nut (3). n Rotate stem counter clockwise until stem is free from the body. Note: The stem will be complete with upper gland (4) the packing (5) and the lower gland (6). n Clean and inspect all metal parts for nicks, scratches, etc., particularly the stem tip and the valve seat. Discard any parts that are damaged, and replace them with authorized HAM-LET parts. n Discard the stem packing and replace it with authorized HAM-LET parts. Re-assembly Reverse steps above, taking care to lubricate all parts with an appropriate lubricant.

Note: Factory valves are tested at 1,000 psig using N2. No leakage from seat or stem is allowable after 1 minute with the valve immersed in water.
6. Installation Threaded Valves n On taper threads, use a conventional thread sealant such as Teflon tape or an appropriate alternative that is compatible with the application. n Apply a wrench to the body and connecting nut. Do not use the handle to tighten the connection. LET-LOK Valves Ensure the tubing is cut square and that it is de-burred. n Ensure the tubing is located firmly in the connection. n From the finger-tight position, rotate the nut a full 1 1/4 turn. Note: For sizes 3/16 inch (4mm) or less, rotate the nut 3/4 turn only. n Apply a wrench to the body and connecting nut. Do not use the handle to tighten the connection.
n

342

INSTALLATION INSTRUCTIONS

H-400 SERIES
CHECK VALVES

1. Use For maximum valve life, use the valve only within the stated pressure and temperature range, and in accordance with the corrosion resistance of the material. Give particular attention to the compatibility of the O-ring material. 2. Disassembling and Cleaning the Valve A non-return valve can trap fluids within the body. If the valve has been used in hazardous media service, remove with great care and take appropriate decontamination measures. All persons involved in the removal and disassembly of the valve should wear proper protective clothing, such as gloves, aprons, face shields, etc. 3. Replacing Seats, Seals and Springs H-400 valves are designed to give optimum life. Should the valve reveal leaks across the seat: A. Place the body securely in a vise, holding on the hexagon flats. With an appropriate size wrench, unscrew the end. Remove the upper (body) and poppet O-rings. Clean and dry all parts, taking particular care that the seat is not damaged. B. To rebuild the valve: Replace O-rings. Lubricate the threads and outer surface of the poppet with Halocarbon 27 oil, or an alternative as appropriate for the flowing medium. Reassemble poppet and spring into the body. Reassemble the end to the body using a torque wrench set to 20 ft. lb (50 NM). C. Should the valve exhibit opening at less than the stated cracking pressure, follow steps 3A and 3B, replacing the spring with a factory-supplied component. 4. Testing Test all valves for functionality before placing them into service. Using clean, dry nitrogen, pressurize inlet of valve to cracking pressure. Acceptance criterion: valve does not pass nitrogen at 20% of cracking pressure when immersed in water for one (1) minute. Using clean, dry nitrogen, pressurize the outlet of the valve to 2000 psig.

Acceptance criterion: no leakage from the body/end connection when it is immersed in water for one (1) minute. 5. Installation Apply wrench on hexagon adjacent to the end being connected. Do not grip the body with vise grips or similar tools. Warning! For Your Safety The system designer and user have the sole responsibility to select products suitable for their special application requirements to ensure the proper installation, operation and maintenance of the product. Application details, material compatibility and product ratings should all be considered in the individual selection. Improper selection or use of products can cause property damage or personal injury.

343

INSTALLATION INSTRUCTIONS

H-500 SERIES
3-PIECE BALL VALVES

1. Use: 1.1 For maximum valve life, use the valve only within the stated pressure and temperature range, and in accordance with the corrosion resistance of the material. Give particular attention to the compatibility of the O-ring material. 2. Manual Operation 2.1 To open or close the valve, turn the handle 1/4 turn (90 degrees). A. When the valve is in Open Position, the handle is parallel (in-line) with the valve or pipeline. B. When the valve is in Closed Position, the handle is perpendicular (crossed) to the valve or pipeline. 3. Automated Operation 3.1 Check any valve with an actuator for valve-stem alignment. Angular or linear misalignment will result in high operational torque and unnecessary wear on the stem seal. 4. Disassembling & Cleaning the valve: A ball valve can trap fluids in ball cavity when it is in the closed position. If the valve has been used in hazardous medium, decontaminate it before disassembly. A. Relieve the line pressure. B. Place the valve in half-open position and flush the line to remove any hazardous material from the valve. C. All persons involved in the removal and disassembly of the valve should wear proper protective clothing, such as face shields, gloves, aprons, etc. Replacing Seats, Joint Gaskets, Stem Seal and Stem Packing Model H-500 is designed with Belleville washers for automatic seal wear compensation. If there is any sign of leakage from the stem, replace the stem packing and the stem seal. If there is any sign of internal leakage, replace the ball seats. 5.1 When replacing the seats and joint gaskets, refer to the assembly diagram. A. Follow the above Disassembling & Cleaning Instructions (number 4, above). Make sure the pipeline is de-pressurized. B. With the valve in the open position (lever parallel to the axis of the pipe), loosen all the nuts on the 5.

body bolting. Remove all the bolts except one. Swing the body outside the pipe. C. Turn the handle to the half-open position to assist in the removal of the seats. D. Replace with a new set of seats and joint gaskets. E. Swing the body back into position. Replace the removed bolt, and tighten the bolts according to the Bolt Tightening Specification Table on the next page. 5.2 When replacing the stem seal, and stem packing, refer to the assembly diagram. A. Follow the direction for replacing the seats and joint gaskets from 5.1.A to 5.1.C. B. To assist in loosening the stem nut, place a rod of diameter smaller than the ball orifice into the ball orifice. Loosen and remove the top stem nut with a wrench. Remove the stem washer, handle and lock saddle. Place all removed parts in a clean and secure place. C. Loosen and remove the second stem nut with a wrench. Remove the set of Belleville washers. Place all removed parts in a clean and secure place. D. Remove the rod. Turn the valve to the closed position (handle perpendicular to the pipeline). Remove the seats and gaskets. The ball should slide out with a gentle push. Place all removed parts in a clean and secure place. E. Push the stem downward. It should come out through the center body. Remove the stem then remove the stem seal. Thoroughly clean the stem. Replace it with a new stem seal. F. Remove the stem packing from the center body cavity. Thoroughly clean the center body. Insert a new stem packing. G. Replace the stem, the Belleville washers and the gland. Replace the first stem nut. To tighten the nut, hold the stem in place and tighten the nut with a wrench. When tightening the stem nuts, make sure they are snug and the Belleville washer is compressed to the maximum extent. Replace the lock saddle, the stem handle, the stem washer and the top stem nut. Tighten the top stem nut with a wrench.

344

INSTALLATION INSTRUCTIONS

3-PIECE BALL VALVES

H-500 SERIES

(Contd)

H. Turn the valve to the closed position (handle

perpendicular to the pipeline). Replace the ball. Turn the valve to the open position (handle parallel to the pipeline). Replace the seats and joint gaskets. I. Swing the center body back into position. Replace the removed bolts and nuts. Tighten the nuts according to the Bolt Tightening Specification Table. 6. General Information for On-Site Installation: 6.1 The valve may be fitted in any position on the pipeline. 6.2 To prevent damage to the seats and ball surface, make sure the pipeline is flushed, free of dirt, burrs and welding residues before installing the valve. 7. Installation of Threaded Valves 7.1 Use a conventional sealant, such as hemp core, Teflon, etc. 7.2 Apply a wrench to the hexagon end of the valve only. Tightening by using the valve body or handle can seriously damage the valve. 7.3 For applications where the screwed end valves are back-welded on site, dismantle these valves according to the instructions for weld end valves. 8. Installation of weld end valves 8.1 Tack-weld the valve onto the pipe in four points on both end caps. 8.2 With the valve in open position (lever parallel to the axis of the pipe), loosen all the nuts on the body bolts. Remove all the bolts except one. Swing the body outside the pipe. 8.3 Turn the handle to the half-open position to assist in the removal of the seats and joint gaskets. 8.4 Turn the handle to the closed position and remove the ball. 8.5 Place all removed parts in a clean and secure place. 8.6 Replace the body and the removed bolt. Tighten all nuts slightly. To prevent any leakage to the body joints after welding, make sure that the body and the end caps remain perfectly parallel.

8.7 Finish welding both end caps onto the pipe. 8.8 After the pipeline and valve cool, clean the end

caps, then remove the previous, and replace bolt. Swing out the body. Turn the valve to the closed position, then replace the ball. Turn the valve to the open position and replace seats and joint gaskets. 8.9 After you have replaced the seats, joint gaskets and ball, swing the body into position, replace the removed bolts and nuts, and tighten the nuts according to the Bolt Tightening Specification Table.

Bolt Tightening Specification Table: Tighten the body bolts of the valve evenly. Tighten one-side snugly, then tighten the one diagonal across. Repeat for the other bolts, bringing them all down tightly in sequence to the torque shown up:
Valve Size Torque (In LB) Torque (N m)

1/4" to 3/4" 72 to 75

8.1 to 8.5

1"

168 to 176 19.0 to 19.9

Warning! For Your Safety The system designer and user have the sole responsibility to select products suitable for their special application requirements to ensure the proper installation, operation and maintenance of the product. Application details, material compatibility and product ratings should all be considered in the individual selection. Improper selection or use of products can cause property damage or personal injury.

345

INSTALLATION INSTRUCTIONS

H-700 SERIES

BALL VALVES WITH LOCKING DEVICE

1. Use For maximum valve life, use the valve only within the stated pressure and temperature range, and in accordance with the corrosion resistance of the material. 2. Operation To open or close the valve, turn the handle 1/4 turn (90). 3. Cleaning the Valve A ball valve can trap fluids in ball cavity when it is in the closed position. If the valve has been used in hazardous medium, decontaminate it before disassembly. All persons involved in the removal and disassembly of the valve should wear appropriate protective clothing, such as face shields, aprons, gloves, etc. 4. Replacing Seats and Stem Seals. Type H-700 is designed with Belleville washers for automatic stem-seal wear compensation. If there are signs of leakage through the stem area, replace stem seals. If there are signs of internal leakage, replace the seat seals. 5. Procedures Disassembly With the valve clamped firmly in a vise: n Remove the nut, spring washer, handle, Belleville washer, thrust washer and top packing. Place in a secure, clean area. n Remove the end connection/internal nut and body seal. n Rotate the ball to the closed position and remove the ball and seat seals. Inspect the ball for any surface damage. If there are no nicks, scratches or other surface damage, place the ball in a clean, secure area. n Remove the stem, and lower the packing from the body cavity. n Scrap all plastic parts and replace them with authorized HAM-LET parts. n Clean and inspect all metal parts, and replace as necessary with authorized HAM-LET parts.

Reassembly Reverse the steps above, taking care to lubricate all parts with an appropriate lubricant. Notes: The end connection/internal nut must be closed firmly. n The stem nut must be closed with sufficient torque to deflect the belleville washer.
n

Warning! For Your Safety The system designer and user have the sole responsibility to select products suitable for their special application requirements to ensure the proper installation, operation and maintenance of the product. Application details, material compatibility and product ratings should all be considered in the individual selection. Improper selection or use of products can cause property damage or personal injury.

346

INSTALLATION INSTRUCTIONS

H-6800 SERIES

INSTRUMENTATION BALL VALVES

General Note

When a ball valve is removed or installed in a tube system, a back-up wrench (spanner) must be used on the end connector, NOT on the valve body. Tube Fitting Connectors (LET-LOK Twin-Ferrule Compression Fittings) 1. Insert the tubing, nesting it in the counterbore. 2. Ensure that the nut is finger tight, and mark the nut for reference. 3. Now tighten the nut 1 1/4 turns. Note: For sizes 1/16 to 3/16 inch (2 to 4 mm), tighten 3/4 turn only from finger tight.
Taper Threaded Connectors (NPT, BSPT, Male or Female) 1. On the male thread of the connector, apply PFTE

Installation of Panel-Mounted Valves

Valve Size 1/4 3/8 1/2 Max. Panel Thickness 11/32 (9mm) Panel Hole Diameter 13/16 (2mm)

1. Remove the handle by turning the set screw counter

clockwise using the appropriate hex-socket tool.

2. Insert the valve though the panel hole and assemble

tape or high-quality sealing compound. When PFTE tape is used, no more than two full turns of the tape should be applied. The tape must not overhang the end of the connector. 2. Screw the valve and connector together until hand tight. 3. With the proper size wrench (spanner), holding both sides of the connector (not the valve body), continue to tighten until a leak-tight joint is achieved.
Welded Connectors 1. We recommend disassembling all valves prior to

the panel nut. Note: If the valve is mounted to a thin panel, it may be necessary to fit a spacer (washer) to the valve to allow proper engagement of the panel nut. 3. If required, adjust the stem packing as explained above. 4. Replace the handle and retighten the set screw. Maximum Allowable Working Pressures and Temperatures
Seat Material Valve Body Material

Brass TFM 1600 (Teflon) PCTFE (KEL-F )

Stainless Steel 2,800 psig@100F 6,000 psig@100F 6,000 psig@100F

2,800 psig@100F 3,000 psig@100F 3,000 psig@100F

welding in order to avoid damage to seats and seals. 2. If the valve must be welded when fully assembled, put the valve in the full open position, and continuously purge it with cool gas. People who have been trained in established procedures should perform all the welding tasks. 3. For socket weld ports: insert the tube into the connector until it bottoms out against the stop, then pull it back approximately 1/16 inch (1.5 mm) and weld. This will help to avoid excess static stress.
Packing Adjustment

PEEK

For allowable pressure at various temperatures, see graph in main catalogue. Warning! For Your Safety Select the right component for safety's sake: The total design of the system must be taken into consideration when selecting components in order to ensure that your Ham-Let products provide safe, trouble-free operation. It is the responsibility of the system designer and the user to consider the compatibility of the materials, of the components and system, the function of the component, apprpriate ratings and to ensure proper installation, operation and maintenance. Improper selection or use of products can cause property damage or personal injury, in respect of which the system designer and/or the user shall be solely liable and responsible.

Due to the varied service applications of the valve, packing adjustment may be occasionally necessary. We recommend Initial adjustment after installation and prior to start-up. 1. Remove the handle by turning the set screw counter clockwise using the appropriate hex socket tool.
2. Tighten the packing nut 1/8 to 1/4 turn. 3. Replace the handle and retighten the set screw.

347

INSTALLATION INSTRUCTIONS

H-900 SERIES
RELIEF VALVES

INTRODUCTION

The H-900 Series Relief Valves are designed and tested in accordance with MSS standard SP-99-1994 (R2005) (Instrument Valves). This type of valves is intended for use under relatively low operating pressures (ranging from 10 psig to 225 psig), unfavorable working conditions and can be implemented in either gas or liquid applications. The valves are manufactured from ASTM-A276 body construction and are available in male and female NPT / BSPT pipe threads and LetLok (compression) connectors. General H-900 series is a relief valve intended for use in low-pressure applications. The valve is normally closed and opens when system pressure reaches a set level. It then returns to the closed position when the system pressure falls bellow the set level. Features n Made from St.St 316. n Service pressure up to 300psig. n Available set pressures between 10 psig and 225 psig (0.69 to 15.5 Bar). n Available in male and female NPT / BSPT pipe threads and Let-Lok (compression) connectors. n Available sizes: 1/4" or 6mm. Cleaning / Packaging Ham-Let H-900 Series Relief Valves are treated with HamLet Passivation Cleaning and Packaging (Procedure 8075); Oxygen Cleaning and Packaging (Procedure 8055) is available upon request. Testing The designs of the Ham-Let H-900 Series Relief Valves have been tested for proof, burst and leakage. Every relief valve is factory-tested for proper set and resealing performance.

SAFETY INSTRUCTIONS
General n All installation and/or maintenance operations must be obtained when the system pressure is fully relived. n All installation and/or maintenance operations must follow User Manual Instructions. n Use only appropriate tools, which are designed and built for the specific operation. n Plan your action carefully in advance, especially when dealing with extreme temperature, pressure and corrosive materials. n Use a proper protection and safety devices during maintenance. Volume considerations While evaluating volume to be relieved, all system volumes should be considered, i.e.: system lines, pumps, bulk tanks etc Warning! For Your Safety When selecting individual components, the total design of the system must be taken into consideration in order to ensure that your Ham-Let product will provide a safe and trouble-free operation. It is the responsibility of both the system designer and user to consider the inter-compatibility of the materials, components and systems, and the intended function of each component. Please ensure the component's appropriate ratings and their proper installation, operation and maintenance. Improper selection or use of products may cause property damage or personal injury, in regard of which the system designer and/or the user shall be solely liable and responsible. Follow all enclosed instructions and refer to the product catalog for detailed product specifications.

348

INSTALLATION INSTRUCTIONS

RELIEF VALVES

H-900 SERIES

(Contd)
1

2 3

H-900 - MATERIALS
No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part
Cap Plug Adjustment Cap Cap Lable Spring Locking Nut Spring Support Disc Bonnet O-Ring Stem O-Ring Retaining Ring Poppet Seal Insert Packing Ring Body

Qty.
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Valve Body Material

Polypropylene St.St. 316 Polyester St.St. 302 St.St. 316 St.St. 316 St.St. 316 Viton (Fluorocarbon) St.St. 316 Viton (Fluorocarbon) PH1-57 Mo St.St. 316 )Viton (Fluorocarbon St.St. 316 PTFE St.St. 316 St.St. 316

9 10 11
L

DIMENSIONS
Description
H900 H900 H985 H995

Connection / size
inlet outlet H

Dimensions mm:
N S

1/4 LET-LOK 6MM LET-LOK 1/4 Male NPT 1/4 Male NPT

1/4 LET-LOK 6MM LET-LOK 1/4 Female NPT 1/4 LET-LOK

37 37 32 32

39 39 30 39

50 50 40 50

105 105 100 100

12

13 14 15

16

17

349

INSTALLATION INSTRUCTIONS

H-900 SERIES
RELIEF VALVES

(Contd)

MAINTENANCE
Tool requirement n 3/4" wrench. n 5/16" Allen (Hex) key. n O-ring installation and removal tools. n Retaining ring installation and removal tool. Cracking Pressure Adjustment 1. Thread adjustment cap (3) onto the bonnet (7) - 9 full turns. 2. Tighten locking nut (5) against the adjustment cap (2) and test for set pressure. 3. Relieve system pressure; unthread the adjustment cap (2) as needed (use manual or 3/4" wrench). Repeat procedure as necessary to obtain desired set pressure. 3.1 A clockwise rotary of the adjustment cap (2) will increase the spring force and the cracking pressure of the valve. 3.2 A counter-clockwise rotary of the adjustment cap (2) will decrease the spring force and the cracking pressure of the valve. 4. Tighten locking nut (5) against the adjustment cap (2). 5. Lock wire the adjustment cap (2) and valve body (17) to maintain relief setting. H-900 Series Spring installation / replacement Warning: Relieve system pressure before any valve maintenance. Content: 1 x Spring (4) 1 x Label (3) 1 x Lock wire 1 x Lead 1. Select the desired spring according to the Nominal Cracking Pressure Range as shown at the "material of construction" section above. 2. Loosen the locking nut (5) with a 3/4" wrench (clockwise) and remove the adjustment cap (2) with a 3/4" wrench (counter-clockwise) from the bonnet (7). 3. Remove the spring (4). 4. Make sure all components are clean of burrs. 5. Insert the selected spring (4) inside the bonnet (7).

6. Replace existing cracking pressure range label (3) with a new one. Ensure that the pressure range, which is written on the Label (3) is in compliance with the installed spring (4) range. 7. Screw adjustment cap (2) onto bonnet (7) with 3/4" wrench. 8. Perform Cracking Pressure Adjustment procedure described above. Valve Testing guidelines. 1. Connect the Relief Valve inlet to the pressure source. 2. Connect Relief Valve outlet to any leak detecting device. 3. Increase the inlet pressure slowly. 4. Verify that an initial flow from the outlet will occur at the pre-set pressure. 5. Repeat adjustment procedure as necessary to set the desired cracking pressure. Note: For proper maintenance of the H-900 Series Relief Valves, a service cycle and setting validation of at least once each 1/2 year is recommended. The inspection, maintenance and testing can be incorporated into the annual inspection procedure to ensure proper operation and many years of trouble-free service. The life span of the main valve seal depends upon varied factors, such as: n Chemical resistance of the seal to the system medium n The volume of fluid, passed through the valve. n The operating pressure n The quantity of dirt and other foreign particles present.

H-900 SERIES SEAL KIT REPLACEMENT.

Content: 1 x O-ring (8) 1 x O-ring (10) 1 x Retaining ring (11) 1 x Bonded poppet (12)

350

INSTALLATION INSTRUCTIONS

H-900 SERIES
RELIEF VALVES

(Contd)

Disassembly and Seal Removal Warning: Relieve system pressure before any valve maintenance. 1. Clamp the valve body in a wise. 2. Remove adjustment cap (2). 3. Remove bonnet (7) from the body (17) - use a 3/4" wrench and rotate counter-clockwise for opening. 4. Remove stem (9) by pulling it from the bonnet (7) bore. 5. Remove O-ring (8) from the bonnet (7). 6. Remove carefully the retaining ring (11) from the bonnet (7). Caution: The retaining ring is a spring stainless clip. Do not direct it at a person. 7. Remove the o-ring (10) from the bonnet (7). 8. Remove bonded poppet (12) by turning the valve upside down. 9. Discard all soft (wetted) parts. 10. Inspect all parts for nicks, scratches and dents. Discard as appropriate. Replace with Ham-Let parts only.

Reassembly and seal installation 1. Clamp the valve body in a wise. 2. Make sure all parts are clean before installation. 3. Install new bonded poppet (12) in the body (7) (upright position), when the seal of the bonded poppet is faced downward. 4. Install new o-ring (10) (Lubricate with system compatible lubricant) into the bonnet (7). 5. Install new retaining ring (11) (make sure the teeth are pointing away from the quad-ring). 6. Insert the stem (9) into the bonnet (7) through o-ring (9) until it bottoms. 7. Install new o-ring (8) on the bonnet (7) (Lubricate with system compatible lubricant). 8. Install bonnet (7) into body (17) and tighten bonnet to 68N*m (600lb.*in). 9. Perform adjustment procedure before installing in the system.

Troubleshooting Warning: Relieve system pressure before any valve maintenance.

Symptom
Relief valve remains open Relief valve opens below set pressure

Possible Causes
Leakage through bonded poppet seal (13) Loss of spring force/Mechanical grip.

Corrective Action
Replace bonded poppet (12) Remove adjustment cap (2). Clean spring (4), bonnet (7) and adjustment cap (2) from particles.

Relief valve opens above set pressure Unable to control the valve for shut-off

Friction on the mechanical working mechanism. Check auxiliary systems for leaks, and readjust Leakage through any attached auxiliary system pressure. such as emergency shutdown system, remote Disassemble, clean parts and perform cracking operators, etc. pressure adjustment procedure. The spring range is too low. Choose H-900HP Series valve with higherpressure range spring. Choose a larger size of Relief valve.

Relief valve too small. Unable to relieve the pressure from Too much gas capacity to complete cycle. the system after cracking

n For oxygen applications work shall be carried out according to procedures for working with oxygen. In case spare kits are ordered for oxygen clean valves, such kits have to be ordered as oxygen clean.

351

INSTALLATION INSTRUCTIONS

H-900 HP SERIES

HIGH-PRESSURE RELIEF VALVES

INTRODUCTION

The H-900HP Series Relief Valves are designed and tested in accordance with MSS standard SP-99-1994 (R2005) (Instrument Valves).This type of valves is intended for use under extremely high operating pressures (ranging from 50 psig to 6000 psig) and unfavorable working conditions, and can be implemented in either gas or liquid applications. The valves are manufactured from ASTM-A276 body construction, and are available in male and female NPT / BSPT pipe threads and LetLok (compression) connectors. General H-900HP series is a relief valve intended for use in high-pressure applications. The valve is normally closed and opens when system pressure reaches a set level. It then returns to the closed position when the system pressure falls bellow the set level. Features n Made from St.St 316. n Service pressure up to 6000 psig. n Available set pressures between 50 psig and 6,000 psig (3.44 to 413.8 Bar). n Color-coded springs for each pressure range n Replaceable springs for a wide range of pressures n Available in male and female NPT / BSPT pipe threads and Let-Lok (compression) connectors. n Available sizes: 1/4" or 6mm. Cleaning / Packaging Ham-Let H-900HP Series Relief Valves are treated with Ham-Let Passivation Cleaning and Packaging (Procedure 8075); Oxygen Cleaning and Packaging (Procedure 8055) is available upon request. Testing The designs of the Ham-Let H-900HP Series Relief Valves have been tested for proof, burst and leakage. Every relief valve is factory-tested for proper set and resealing performance.

SAFETY INSTRUCTIONS
General n All installation and/or maintenance operations must be obtained when the system pressure is fully relived. n All installation and/or maintenance operations must follow User Manual Instructions. n Use only appropriate tools, which are designed and built for the specific operation. n Plan your action carefully in advance, especially when dealing with extreme temperature, pressure and corrosive materials. n Use a proper protection and safety devices during maintenance. Volume considerations While evaluating volume to be relieved, all system volumes should be considered, i.e.: system lines, pumps, bulk tanks etc. Warning! For Your Safety Select the right component for safety's sake: The total design of the system must be taken into consideration when selecting components in order to ensure that your Ham-Let products provide safe, trouble-free operation. It is the responsibility of the system designer and the user to consider the compatibility of the materials, of the components and system, the function of the component, apprpriate ratings and to ensure proper installation, operation and maintenance. Improper selection or use of products can cause property damage or personal injury, in respect of which the system designer and/or the user shall be solely liable and responsible.

352

INSTALLATION INSTRUCTIONS

H-900 HP SERIES

(Contd) HIGH-PRESSURE RELIEF VALVES

2 3 4

H-900 HP MATERIALS
No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part
Cap Plug Label Adjustment Cap Spring Lower Spring Button Locking Nut Bonnet O-Ring Quad Ring Retaining Ring Poppet Clamps Screw O-Ring Insert Body

Qty.
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Valve Body Material

PTFE PVC St.St 316 St.St. 302,17-7PH St.St 316 St.St 316 St.St 316 Viton (Fluorocarbon) Viton (Fluorocarbon) PH15-7Mo St.St 316 St.St 316 Viton (Fluorocarbon) St.St 316 St.St 316

11

5 6

9 10

7 8

12 13 14 15

DIMENSIONS
Description Connection / size
inlet outlet H

Dimensions mm:
N S L

H900-HP 1/4 LET-LOK H900-HP 6MM LET-LOK H985-HP H995-HP 1/4 Male NPT 1/4 Male NPT

1/4 LET-LOK 6MM LET-LOK 1/4 Female NPT 1/4 LET-LOK

37 37 32 32

39 39 30 39

50 50 40 50

105 105 100 100

NOMINAL CRACKING - PRESSURE RANGE

psig
50-350 350-750 750-1500 1500-2250 2250-3000 3000-4000 4000-5000 5000-6000

Bars
24 - 3.4 24 - 51.5 103 - 51.5 103 - 155 206 - 155 206 - 275 344 - 275 344 - 413

Spring Designator
A B C D E F G H

Color
White Blue Gold Turquoise Green Red Silver Black

353

INSTALLATION INSTRUCTIONS

H-900HP SERIES

(Contd) HIGH-PRESSURE RELIEF VALVES

MAINTENANCE
Tool requirement n 3/4" wrench. n 1/4" Allen (Hex) key. n O-Ring installation and removal tools. n Retaining ring installation and removal tool. Cracking Pressure Adjustment 1. Thread adjustment cap (3) onto the bonnet (7) - 9 full turns. 2. Tighten locking nut (6) against the adjustment cap (3) and test for set pressure. 3.Relieve system pressure; unthread the adjustment cap (3) as needed (use manual or 3/4" wrench). Repeat procedure as necessary to obtain desired set pressure. 3.1 A clockwise rotary of the adjustment cap (3) will increase the spring force and the cracking pressure of the valve. 3.2 A counter-clockwise rotary of the adjustment cap (2) will decrease the spring force and the cracking pressure of the valve. 4. Tighten locking nut (6) against the adjustment cap (3). 5. Lock wire the adjustment cap (3) and valve body (15) to maintain relief setting.

6. Replace existing cracking pressure range label (2) with a new one. Ensure that the pressure range, which is written on the Label (2) is in compliance with the installed spring (4) range. 7. Screw adjustment cap (3) onto bonnet (7) with 3/4" wrench. 8. Perform Cracking Pressure Adjustment procedure described above. Valve Testing guidelines. 1. Connect the Relief valve's inlet to the pressure source. 2. Connect Relief valve's outlet to any leak detecting device. 3. Increase the inlet pressure slowly. 4. Verify that an initial flow from the outlet will occur at the pre-set pressure. 5. Repeat adjustment procedure as necessary to set the desired cracking pressure. Note: For proper maintenance of the H-900HP Series Relief Valves, a service cycle and setting validation of at least once each 1/2 year is recommended. The inspection, maintenance and testing can be incorporated into the annual inspection procedure to ensure proper operation and many years of trouble-free service. The life span of the main valve seal depends upon varied factors, such as: n Chemical resistance of the seal to the system medium n The volume of fluid, passed through the valve. n The operating pressure n The quantity of dirt and other foreign particles present.

H-900 HP Series Spring installation / replacement Warning: Relieve system pressure before any valve maintenance. Content: 1 x Spring (4) 1 x Label (3) 1 x Lock wire 1 x Lead 1. Select the desired spring according to the Nominal Cracking Pressure Range as shown at the "material of construction" section above. 2. Loosen the locking nut (6) with a 3/4" wrench (clockwise) and remove the adjustment cap (3) with a 3/4" wrench (counter-clockwise) from the bonnet (7). 3. Remove the spring (4). 4. Make sure all components are clean of burrs. 5. Insert the selected spring (4) inside the bonnet (7).

H-900 HP SERIES SEAL KIT REPLACEMENT.

Content: 1 x O-Ring (8) 1 x Quad-ring (9) 1 x Retaining ring (10) 1 x O-Ring (13)

354

INSTALLATION INSTRUCTIONS

H-900 HP SERIES

(Contd) HIGH-PRESSURE RELIEF VALVES

Disassembly and Seal Removal Warning: Relieve system pressure before any valve maintenance. 1. Clamp the valve body in a wise. 2. Remove adjustment cap (3). 3. Remove bonnet (7) from the body (15) - use a 3/4" wrench and rotate counter-clockwise for opening. 4. Remove poppet (11) by pulling it from the bonnet (7) bore. 5. Remove O-ring (8) from the bonnet (7). 6. Remove carefully the retaining ring (10) from the bonnet (7). Caution: The retaining ring is a spring stainless clip. Do not direct it at a person. 7. Remove the Quad-ring (9) from the bonnet (7). 8. Remove the clamp screw (12) from the body (15). Rotate the clamp screw counter-clockwise for opening. Use a 1/4" Allen (hex) key. 9. Remove O-ring (13) from the body (7). 10. Discard all soft (wetted) parts. 11. Inspect all parts for nicks, scratches and dents. Discard as appropriate. Replace with Ham-Let parts only

Reassembly and seal installation 1. Clamp the valve body in a wise. 2. Make sure all parts are clean before installation. 3. Install new O-ring (13) in the body (7) (Lubricate with system compatible lubricant). 4. Thread clamp screw (12) in the body (15). Tight permanently with 1/4" Allen (hex) key. 5. Install new quad-ring (9) (Lubricate with system compatible lubricant) into the bonnet (7). 6. Install new retaining ring (10) (make sure the teeth are pointing away from the quad-ring). 7. Insert the poppet (11) into the bonnet (7) through the quadring (9) until it bottoms. 8. Install new o-ring (8) on the bonnet (7) (Lubricate with system compatible lubricant). 9. Install bonnet (7) into body (15) and tighten bonnet to 68N*m (600lb.*in). 10. Perform adjustment procedure before installing in the system.

Troubleshooting Warning: Relieve system pressure before any valve maintenance.

Symptom
Relief valve remains open Relief valve opens below set pressure

Possible Causes
Leakage through O-Ring seal (13) Loss of spring force/ Mechanical grip.

Corrective Action
Replace O-Ring (13) Remove adjustment cap (3). Clean spring (4), bonnet (7) and adjustment cap (3) from particles.

Relief valve opens above set pressure

Friction on the mechanical working mechanism. Check auxiliary systems for leaks, and readjust Leakage through any attached auxiliary system pressure. such as emergency shutdown system, remote Disassemble, clean parts and perform cracking operators, etc. pressure adjustment procedure. The spring range is too high. The spring range is too low. Relief valve too small. Too much gas capacity to complete cycle. Choose a spring with lower pressure range. Choose a spring with higher-pressure range. Choose a larger size of Relief valve.

Unable to control the valve for cracking Unable to control the valve for shut-off Unable to relieve the pressure from the system after cracking

n For oxygen applications work should be carried out according to procedures for working with oxygen. In case spare kits are ordered for oxygen clean valves, such kits have to be ordered as oxygen clean.

355

INSTALLATION INSTRUCTIONS

H-600 SERIES

T-TYPE & IN-LINE FILTERS

H-600 IN-LINE FILTER

Customer's Instructions for Disassembly and Reassembly Body Filter Element Spring Insert

H-600 FILTER T-TYPE

Customer's Instructions for Disassembly and Reassembly

Insert

Nut Spring Filter Element

Sealing Gasket Sealing Gasket Disassembly Use a suitable wrench to loosen the body from the insert. Then remove the element, spring and sealing gasket. Reassembly 1. Prior to reassembly, clean the filter house and make sure that all other components are clean and free of contaminants. 2. Place the element in the filter body so that the open end of the element is parallel to the element seat diameter. 3. Lubricate the sealing gasket gently. The recommended oil: Fluorolube grade T-80. Put the sealing gasket in its place. 4. Mount the sealing gasket on the insert. 5. Place the spring inside the insert. 6. Close the nut manually. Make sure that the sealing gasket is correctly placed. 7. Use a moment wrench to affix the insert more tightly onto the body, according to the Table below. 8. Connect the filter to the pressure line and check the filter for correct operation. Use liquid leak detectors to ensure there is no leakage.

Body Disassembly Use a suitable wrench to loosen the body from the insert. Then remove the element, spring and sealing gasket. Reassembly 1. Prior to reassembly, clean the filter house and make sure that all other components are clean and free of contaminants. 2. Place the element in the filter body so that the open end of the element is parallel to the element seat diameter. 3. Lubricate the sealing gasket gently. The recommended oil: Fluorolube grade T-80. Put the sealing gasket in its place. 4. Place the spring inside the insert. 5. Close the nut manually. 6. Use a moment wrench to tighten the nut, according to the Table below. 7. Connect the filter to the pressure line and check the filter for correct operation. Use liquid leak detectors to ensure there is no leakage.

Table Nut Tightening Moment lb-in (N-m)

Standard Assembly With no lubrication on the sealing gasket (used for special applications)

Table Nut Tightening Moment lb-in (N-m)

Standard Assembly

With no lubrication on the sealing gasket (used for special applications)

SS
H-600 -1/8 H-600-3mm H-600 -1/4 H-600 - 6mm H-600 -3/8 H-600 -8mm H-600 -10mm H-600 -12mm H-600 -1/2 150 (17) 380 (43)

Brass
135 (15) 345 (39)

SS
530 (60)
H-600R -1/8 H-600R-3mm H-600R -1/4 H-600R - 6mm H-600R -3/8 H-600R -8mm H-600R -10mm H-600R -12mm H-600R -1/2

SS
530 (60)

Brass
470 (53)

SS
575 (65)

Brass
470 (53)

630 (71)

470 (53)

680 (77)

470 (53)

530 (60)

470 (53)

830 (94)

Warning! For Your Safety

The system designer and user have the sole responsibility to select products suitable for their special application requirements to ensure the proper installation, operation and maintenance of the product. Application details, material compatibility and product ratings should all be considered in the individual selection. Improper selection or use of products can cause property damage or personal injury.

356